Control setup device and control setup method

ABSTRACT

According to a certain embodiment, a control setup deice ( 200 ) includes an execution parameter information storage area ( 206   d ) for storing execution parameter information, an SGF table storage area ( 206   b ) for storing SGF tables, a finish spray code table storage area ( 206   c ) for storing finish spray code tables, a composition data storage area ( 206   e ) for storing composition data tables representing composition data of steel type families, and a control setup determiner ( 201   b ) operable when a detemination of a set of control set-points in steel type families is requested, to determine a set of control set-points based on a composition data table, a composition data and a combination of a target plate thickness and a target plate width contained in a setup request signal, first control information, and execution parameter information, and when a determination of a set of control set-points in steel types is requested, to determine a set of control set-points based on second control information, a steel type and a combination of a target plate thickness and a target plate width contained in the setup request signal, and execution parameter information.

FIELD

Embodiments described herein relate generally to a control setup device and a control setup method for setting up control set-points as necessary to implement a rolling process for a rolling material in a hot rolling mill.

BACKGROUND

There are rolled steel products having been used recent years in various applications, involving requirements for rolled product manufacturing makers to produce rolled products adaptive to client demands in the application.

As a client demand there comes, for instance, the strength of rolled product. For automobiles, highly strong steel plates are used in components of the chassis and pillars. Moreover, for those sections subject to a predictive crush in collision, steel plates somewhat low in strength are used to prevent deformations of a passenger section, in order to protect the passenger section which is made up by high-strength members. Further, for outer panels needing a highly precise formation, there is made use of steel plates produced with a low strength for adaptation to facilitate the formation and reduce the return (spring back) after the press, and with a tendency to have an increased strength in the baking finishing.

Not only the strength, but also the surface quality is an essential client demand. For the surface quality to be high, in some hot rolling mills there is performed a lubricated rolling using an oil emulsion between a rolling material and rolls in the finish rolling.

Such being the case, there is a wide variety of client demands to rolled products. Rolled product manufacturing makers need to line up different rolled products with various specifications, affording to produce varieties of rolled products on client demands.

Rolled products produced by hot rolling are made different by changing various rolling conditions, i.e., process parameters for rolling operations. Such process parameters for rolling operations involve determining, for instance, the necessity of use (start or stop) for any pass of descalers equipped in a mill, the necessity of use and the initial flow rates in the use of inter-stand cooling elements installed between stands in a continuous mill, the flow rates of lubricants used in a finishing mill, and the cooling patterns to be used at a run-out table. Hot rolling mills employ such process parameters for rolling operations, as necessary for hot rolling performances to produce varieties of rolled products, in addition to preparing chemical components of rolling materials before casting the rolling materials.

In the patent literature 1 below there is proposed a delivery temperature controller for hot finishing mills for controlling cooling sprays to cool a rolling material.

CITATION LIST Patent Literatures

PTL 1: JP 2001-334304 A

SUMMARY Problem

However, the delivery temperature controller for hot finishing mills described in the patent literature 1 was adapted to control cooling sprays for cooling a rolling material, irrespective of the type of steel of the rolling material being rolled. As a result, it was difficult to produce different rolled products to meet various demanded specifications.

Moreover, in most control systems for controlling hot rolling mills, the configuration has been hierarchical for each function. For instance, control systems have been equipped with a level-0 calculator, a level-1 calculator, a level-2 calculator, and a level-3 calculator in the order from the lowest. The level-0 calculator has been implemented with a drive controller, a hydraulic element, or the like. The level-1 calculator has been implemented with a control-oriented controller as is typified by a PLC (Programmable Logic Controller). The level-2 calculator has been implemented with a controlling computer. The level-3 calculator has been implemented with a computer for production control.

And, for process parameters to be set up for rolling operations in a hot rolling mill, there was employed one of a method (as a first method) of setting parameters from the level-3 calculator being superior in level to the level-2 calculator, and a method (as a second method) of having in the level-2 calculator a set of tables of parameters prepared for each of steel type families grouping steel types, and using a steel type family, a plate thickness, a plate width, or the like as a key to set up a parameter.

However, in the first method, the level-3 calculator had an increased load as an issue. More specifically, the level-3 calculator was a calculator adapted to provide instructions for production in accordance with operations of production managers, and usually used for the production control of an entire plant. Therefore, when put in services to determine parameters for processes of all operations including rolling processes, the level-3 calculator had an increased load as an issue.

Moreover, in the second method by which different products were produced conforming to various specifications, it was difficult to determine parameters into particulars in processes for rolling operation. For instance, it was unable to afford some of those situations in which parameters were wanted to set up for different steel types in a steel type family in different rolling operation processes.

Embodiments herein have been devised in view of such issues, and it is an object thereof to provide a control setup device and a control setup method adapted to determine parameters for rolling operation processes into particulars, allowing for a calculator superior in level to be free from undue loads.

Solution

To achieve the object described, according to a first aspect of embodiments of control setup device, there is provided a control setup device comprising an execution parameter information storage area, a first control information storage area, a second control information storage area, a composition information storage area, and a control setup determiner. The execution parameter information storage area is configured to store therein sets of control set-points for control of control object apparatuses and execution parameter numbers uniquely identifying the sets of control set-points, respectively associated with each other, as execution parameter information. The first control information storage area is configured to store therein one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of steel type families including one or more of steel types having similar characteristics, as first control information. The second control information storage area is configured to store therein one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of the steel types, as second control information. The composition information storage area is configured to store therein for a respective one of the steel type families composition information representing components of the steel type family, as composition information tables. The control setup determiner is configured to operate when supplied with a setup request signal requesting a determination of a set of control set-points in the steel type families from a superior calculator connected to the control setup device, to extract from the composition information table one of the steel type families corresponding to composition information contained in the setup request signal, extract from the first control information one of the execution parameter numbers corresponding to the extracted steel type family and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number, and operate when supplied with a setup request signal requesting a determination of a set of control set-points in the steel types from the superior calculator, to extract from the second control information one of the execution parameter numbers corresponding to one of the steel types and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number.

To achieve the object described, according to a first aspect of embodiments of control setup method, there is provided a control setup method comprising an execution parameter information storage step, a first control information storage step, a second control information storage step, a composition information storage step, and a control setup determination step. The execution parameter information storage step is a step of storing in memory means sets of control set-points for control of control object appartuses and execution parameter numbers uniquely identifying the sets of control set-points, respectively associated with each other, as execution parameter information. The first control information storage step is a step of storing in memory means one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of steel type families including one or more of steel types having similar characteristics, as first control information. The second control information storage step is a step of storing in memory means one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of the steel types, as second control information. The composition information storage step is a step of storing in memory means for a respective one of the steel type families composition information representing components of the steel type family, as composition information tables. The control setup determination step is a step of operating when supplied with a setup request signal requesting a determination of a set of control set-points in the steel type families from a superior calculator connected to a control setup device, to extract from the composition information table one of the steel type families corresponding to composition information contained in the setup request signal, extract from the first control information one of the execution parameter numbers corresponding to the extracted steel type family and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number, and operating when supplied with a setup request signal requesting a determination of a set of control set-points in the steel types from the superior calculator, to extract from the second control information one of the execution parameter numbers corresponding to one of the steel types and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number.

Effect

According to embodiments herein, it is adapted to determine parameters in rolling operation processes into particulars, allowing for a calculator superior in level to be free from undue loads.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram showing a configuration of a hot rolling mill to be controlled in accordance with control set-points set up by a control setup device according to a first embodiment.

FIG. 2 is a block diagram showing configurations of a rough edger and a roughing mill equipped in the hot rolling mill to be controlled in accordance with control set-points set up by the control setup device according to the first embodiment.

FIG. 3 is a block diagram showing a configuration of one of stands in a finishing mill equipped in the hot rolling mill to be controlled in accordance with control set-points set up by the control setup device according to the first embodiment

FIG. 4 is a block diagram showing a configuration of a control system to which the control setup device according to the first embodiment is applied.

FIG. 5 is a block diagram showing a configuration of the control setup device according to the first embodiment

FIG. 6 is a flowchart showing a processing procedure of a control setup process for the control setup device according to the first embodiment.

FIG. 7A is an illustration of a model of the control setup process for the control setup device according to the first embodiment.

FIG. 7B is an illustration of the model of the control setup process for the control setup device according to the first embodiment

FIG. 8A is an illustration of the model of the control setup process for the control setup device according to the first embodiment.

FIG. 8B is an illustration of the model of the control setup process for the control setup device according to the first embodiment

FIG. 9 is a block diagram showing a configuration of a roughing mill equipped with two pairs of roughing rolls involved in a control setup device according to a third embodiment

FIG. 10A is an illustration of a model of a control setup process for the control setup device according to the third embodiment

FIG. 10B is an illustration of the model of the control setup process for the control setup device according to the third embodiment

FIG. 11 is a block diagram showing a configuration of a runout laminar spray cooler involved in a control setup device according to a fourth embodiment

FIG. 12A is an illustration of a model of a control setup process for the control setup device according to the fourth embodiment

FIG. 12B is an illustration of the model of the control setup process for the control setup device according to the fourth embodiment.

DETAILED DESCRIPTION

There will be described control setup devices according to embodiments, with reference to the drawings.

First Embodiment

Description is now made of a control setup device according to a first one of embodiments.

(Configuration)

FIG. 1 shows in a block diagram a configuration of a hot rolling mill to be controlled in accordance with control set-points set up by the control setup device according to the first embodiment

As shown in FIG. 1, the hot rolling mill 20 includes a reheating furnace 1, a primary descaler 2, a rough edger 3, a roughing mill 4, an RTD (Roughing Mill Delivery Temperature) 5, an FET (Finishing Mill Entry Temperature) 6, a crop shear 7, a secondary descaler 8, a finishing mill 9, an FDT (Finishing Mill Delivery Temperature) 10, a runout laminar spray cooler 11, a CT (Coiler Entry Temperature) 12, and a coiler 13.

The reheating furnace 1 is a furnace for heating a rolling material 14. The rolling material 14 is a volume of metal put on a transfer line to transfer, to be rolled at the rough edger 3, the roughing mill 4, and the finishing mill 9. The rolling material 14 undergoes processes in the hot rolling mill 20, where it may be called a slab, a bar, or a coil as usual. Here, it is collectively referred to as a rolling material 14.

The rolling material 14 heated at the reheating furnace 1 has oxide films formed thereon. The primary descaler 2 jets high-pressure water to the rolling material 14, from above and below, to remove oxide films on surfaces of the rolling material 14.

The rough edger 3 rolls the rolling material 14 in a width direction thereof in a view from above the line.

The roughing mill 4 has one or more stands for rolling the rolling material 14 in a vertical direction thereof. In most cases, the roughing mill 4 includes a reversible roller to cope with the need to extend the line length, and the need to provide a plurality of passes (for reciprocation in the transfer direction). The roughing mill 4 is equipped with a descaler for spraying high-pressure water to the rolling material 14 being a half-finished product to remove oxide films on the surfaces. The rolling is subjected to hot temperatures with tendencies to form oxide films, and needs to employ apparatuses as necessary to remove such oxide films. Details will be discussed later on.

The RDT (Roughing Mill Delivery Temperature) 5 measures surface temperatures of the rolling material 14 being rolled as a half-finished product.

The FET (Finishing Mill Entry Temperature) 6 measures surface temperatures of the rolling material 14 at an entry of the finishing mill 9 after the way from the roughing mill 4 to the finishing mill 9, which has a long distance. The temperatures are closely related with material deformation resistances of the rolling material 14, and measured as temperatures in position just before the processing. They may be estimated by a temperature prediction in high precision.

The crop shear 7 cuts head and tail ends of the rolling material 14.

The secondary descaler 8 is equipped at the entry of the finishing mill 9 in consideration of the long distance between the roughing mill 4 and the finishing mill 9. The secondary descaler 8 jets high-pressure water to the rolling material 14, from above and below, to remove oxide films formed on surfaces of the rolling material 14 as rough-rolled, in order for the rolling material 14 to have good surface properties after the finish-rolling.

The finishing mill 9 employed is a tandem type including an array of mill rollers called stands, which are each adapted to vertically roll the rolling material 14 to a targeted plate thickness. The finishing mill 9 is equipped with sprays at and between the stands for suppressing formation of oxide films, and for controlling temperatures. Details will be discussed later on.

The FDT (Finishing Mill Delivery Temperature) 10 measures surface temperatures of the rolling material 14 rolled at the finishing mill 9. For the rolling material 14, the temperatures are closely related with metal textures formed in a finished product, as well as with the quality of material, and should be controlled as necessary

The runout laminar spray cooler 11 is composed of a set of elements for cooling the rolling material 14 with cooling water to control temperatures of the rolling material 14. The element set may involve forced cooling elements in addition to typical runout table cooling elements.

The CT (Coiler Entry Temperature) 12 measures surface temperatures of the rolling material 14 cooled by the runout laminar spray cooler 11. For the rolling material 14, the temperatures are closely related with metal textures formed in a rolled finish product, as well as with the quality of material, and should be controlled as necessary.

The coiler 13 coils up the rolling material 14 to transfer.

FIG. 2 shows, in a block diagram, configurations of the rough edger 3 and the roughing mill 4 equipped in the hot rolling mill 20.

As shown in FIG. 2, the transfer line for the rolling material 14 has thereon an upstream rough descaler 31 installed upstream of the rough edger 3, for jetting high-pressure water to the rolling material 14, from above and below.

Further, the transfer line for the rolling material 14 has thereon a downstream rough descaler 45 installed downstream of the roughing mill 4, for jetting high-pressure water to the rolling material 14, from above and below. The roughing mill 4 is equipped with a pair of first material-rolling roll cooling elements 41 and 42 for spraying water under pressure to an upper rough-rolling roll 4AA, and a pair of second material-rolling roll cooling elements 43 and 44 for spraying water under pressure to a lower rough-rolling roll 4AB.

For the upstream rough descaler 31 and the downstream rough descaler 45, setups are made every pass, as necessary to start or stop. Setups for start are made in accordance with the degree of oxide film development. For typical rolling materials, the rolled products should have as high temperatures as possible. Hence, control set-points are determined to use oxide films in requisite minimum quantifies within permissible ranges. For some steel types, their rolling materials 14 may be given target temperatures to be measured at the RDT (Roughing Mill Delivery Temperature) 5, as requirements for metal textures. For temperature control for this purpose also, there may be use of oxide films.

FIG. 3 shows in a block diagram a configuration of one of stands in the finishing mill 9 equipped in the hot rolling mill 20.

As shown in FIG. 3, the transfer line for the rolling material 14 has thereon inter-stand cooling elements 94 installed downstream in the finishing mill 9, for spraying cooling water to the rolling material 14, from above and below, in variable flow rates to control temperatures of the rolling material 14 between associated stands, and suppress occurrences of secondary scales.

Further, the transfer line for the rolling material 14 has thereon a strip spray 91, a bottom spray 92, and roll gap sprays 93 installed upstream in the finishing mill 9, for spraying cooling water to suppress occurrences of secondary scales.

Further, there are hume suppression sprays 95 installed downstream of the inter-stand cooling elements 94, for spraying cooling water to suppress occurrences of fine mineral dust called hume at the delivery side of the stand.

Further, the finishing mill 9 is equipped with a pair of third material-rolling roll cooling elements 96 a and 96 b for spraying cooling water to an upper finish-rolling roll 9A and a pair of fourth material-rolling roll cooling elements 99 a and 99 b for spraying cooling water to a lower finish-rolling roll 9B.

The roll gap sprays 93 are provided for purposes of preventing occurrences of secondary scales, and preventing roll surfaces from peeling.

The transfer line for the rolling material 14 has thereon roll gap lubrication sprays 97 and 98 installed upstream in the finishing mill 9, for applying an emulsion containing a lubricant to the finish-rolling rolls 9A and 9B or to the rolling material 14. This is done to decrease the coefficients of friction between the rolling material 14 and the finish-rolling rolls 9A and 9B, for reducing abrasion of the finish-rolling rolls 9A and 9B to extend their service lives, and to provide the rolling material 14 with enhanced surface properties.

There have been discussed elements: the upstream rough descaler 31, downstream rough descaler 45, paired first material-rolling roll cooling elements 41 and 42, paired second material-rolling roll cooling elements 43 and 44, inter-stand cooling elements 94, strip spray 91, roll gap splays 93, roll gap sprays 97 and 98, bottom spray 92, fume suppression sprays 95, paired third material-rolling roll cooling elements 96 a and 96 b, and paired fourth material-rolling roll cooling elements 99 a and 99 b, which will be collectively referred to as sprays.

FIG. 4 shows in a block diagram a configuration of a control system to which the control setup device according to the first embodiment is applied.

As shown in FIG. 4, the control system 100 includes a level-0 calculator 104, a level-1 calculator 103, a level-2 calculator 200 with an HMI (Human Machine Interface) 102, and a level-3 calculator 101, in the order from the lowest level. In the hot rolling mill 20, the level-0 calculator 104 may be implemented with, for instance, a hydraulic device or a drive controller. The level-1 calculator 103 may be implemented with, for instance, a control-oriented controller as is typified by a PLC (Programmable Logic Controller). The level-2 calculator 200 is the control setup device, which is implemented with a controlling computer. The level-3 calculator 101 is implemented with a computer for production control.

The level-3 calculator 101 can serve in accordance with user operations to supply the control setup device 200 with a setup request signal. This request signal includes information on a chemical composition based on data of actual measurements made in the preparation of components before a casting of the rolling material 14. The request signal further includes a combination of a target plate thickness and a target plate width, a code steel type, a target size of coil, a set of target temperatures at temperature control points, and a rolling procedure.

The control setup device 200 is operative in accordance with a setup request signal supplied from the level-3 calculator 101 and a combination of operation signals and setup request signals supplied from the HMI 102, to determine a set of parameters for processes in a rolling operation, i.e., control set-points for controlling the hot rolling mill 20, and supply thus determined control set-points to the level-1 calculator 103.

The HMI 102 can serve in accordance with user operations to supply the control setup device 200 with operation signals for e.g. starting or stopping sprays. The HMI 102 can serve also to supply the control setup device 200 with setup request signals for e.g. setting up spray pattern numbers.

The level-1 calculator 103 can serve to control a set of control objects equipped in the hot rolling mill 20 as apparatuses including sprays except for motors, and supply control signals to the level-0 calculator 104 for controlling motors equipped in the hot rolling mill 20.

The level-0 calculator 104 can serve to control apparatuses including the motors in the hot rolling mill 20 in accordance with a set of control signals supplied from the level-1 calculator 103.

FIG. 5 shows in a block diagram a configuration of the control setup device 200 according to the first embodiment.

As shown in FIG. 5, the control setup device 200 according to the first embodiment includes a ROM 202, a RAM, a first network interface 204 for material-rolling, a second network interface 205 for material-rolling, and a hard disc 206, which are interconnected through a bus 300.

The ROM 202 is made up by non-volatile semiconductors or the like for storing an operation system to be executed at a CPU 201.

The RAM 203 is made up by volatile semiconductors or the like for storing data as necessary for the CPU 201 to execute various processes.

The first network interface 204 for material-rolling is a device for communications, such as a LAN card or a serial port. The first network interface 204 for material-rolling affords to interconnect with the level-3 calculator 101 and the level-1 calculator 103, permitting communications with the level-3 calculator 101 and the level-1 calculator 103.

The second network interface 205 for material-rolling is a device for communications, such as a LAN card or a serial port. The second network interface 205 for material-rolling affords to interconnect with the HMI 102, permitting communications with the HMI 102.

The hard disc 206 has control programs stored therein for the CPU 201 to execute.

The hard disc 206 includes a GCI table storage area 206 a, an SGF table storage area 206 b, a finish spray code table storage area 206 c, an execution parameter table storage area 206 d, and a composition data storage area 206 e, as necessary to function.

The GCI table storage area 206 a stores steel type codes and spray pattern numbers associated with each other. Each spray pattern number is a number that uniquely identifies a spray pattern associated with an execution parameter number corresponding to a combination of a target plate thickness and a target plate width, for e.g. each steel type or each steel type family.

The SGF table storage area 206 b stores (as first control information) SGF tables each listing spray patterns associated with execution parameter numbers each corresponding to a combination of a target plate thickness and a target plate width, for each steel type family that includes one or more of steel types having similar characteristics.

The finish spray code table storage area 206 c stores (as second control information) finish spray code tables each listing spray patterns associated with execution parameter numbers each corresponding to a combination of a target plate thickness and a target plate width, for each steel type family.

The execution parameter table storage area 206 d stores sets of control set-points for controlling sprays and execution parameter numbers uniquely identifying the sets of control set-points, as execution parameter information. The sets of control set-points and the execution parameter numbers are associated with each other. Control set-points combined in a set for controlling sprays may each be, for instance, a set value instructing a start or stop to a spray or an initial flow rate to the spray.

The composition data storage area 206 e has, for each steel type family, information on components of the steel type family stored in the form of a composition data table.

The CPU 201 operates as a central controller for the control setup device 200. The CPU 201 operates to have the RAM 203 store therein a setup request signal supplied from the level-3 calculator 101 and operation signals supplied from the HMI 102.

The CPU 201 includes an input identifier 201 a and a control setup determiner 201 b, as they are necessary for the function.

The input identifier 201 a operates with a decision that a control setup period is reached, to read a setup request signal and operation signals stored in the RAM 203. On bases of the read setup request signal and operation signals, the input identifier 201 a operates to determine for each spray, whether or not an operation signal is directly input from the HMI 102, whether or not a spray pattern number is directly input from the HMI 102, whether or not a spray pattern number is directly input from the level-3 calculator 101, and/or whether or not a “0” is indicated by a spray pattern number corresponding to a steel type code contained in the setup request signal supplied from the level-3 calculator 101.

The control setup determiner 201 b has a setup request signal supplied as a request requesting a determination of a set of control set-points in the steel type families, from the level-3 calculator 101 connected to the control setup device 200. In other words, when a “0” is indicated by the spray pattern number corresponding to a steel type code contained in the setup request signal supplied from the level-3 calculator 101, the control setup determiner 201 b operates to extract, from a composition data table, a steel type family that corresponds to a composition data contained in the setup request signal. The control setup determiner 201 b further operates to extract, from an SGF table as a piece of first control information, an execution parameter number that corresponds to the extracted steel type family, and to a combination of a target plate thickness and a target plate width contained in the setup request signal. The control setup determiner 201 b still operates to determine from execution parameter information, a set of control set-points that corresponds to the extracted execution parameter number.

Further, the control setup determiner 201 b has a setup request signal supplied as a request requesting a determination of a set of control set-points in the steel types from the level-3 calculator 101. In other words, when the spray pattern number corresponding to a steel type code contained in the setup request signal supplied from the level-3 calculator 101 is else than the “0”, the control setup determiner 201 b operates to extract, from a finish spray code table as a piece of second control information, an execution parameter number that corresponds to the steel type, and to a combination of a target plate thickness and a target plate width contained in the setup request signal. Then, the control setup determiner 201 b operates to determine from execution parameter information, a set of control set-points that corresponds to the extracted execution parameter number.

(Operations)

Description is now made of operations of the control setup device 200 according to the first embodiments.

FIG. 6 shows in a flowchart a processing procedure of a control setup process for the control setup device according to the first embodiment

As shown in FIG. 6, the input identifier 201 a in the control setup device 200 operates (at a step S101) to determine whether or not a control setup period is reached. Here, the control setup period is a period for the control setup device 200 to execute a control setup to the level-1 calculator 103.

If it is determined at the step S101 that the control setup period is reached (in the case of YES), the input identifier 201 a operates (at a step S103) to read a setup request signal and operation signals stored in the RAM 203.

Then, the input identifier 201 a operates (at a step S105) on bases of the operation signals read at the step S103, to determine for a respective spray whether or not an operation signal is directly input from the HMI 102. More specifically, the input identifier 201 a determines whether or not the read operation signals include an operation signal from the HMI 102 requesting a start or stop operation to the spray, or an operation signal requesting a setup of an initial flow rate to the spray.

If it is determined at the step S105 that an operation signal for the spray is directly input from the HMI 102 (in the case of YES), the control setup determiner 201 b operates (at a step S107) to make the level-1 calculator 103 set up a control for the spray via the first network 204 for material rolling in accordance with the operation signal for the spray. The operation signal based on may be e.g. an operation signal instructing a start of the strip spray 91, or an operation signal for setting an initial flow rate of either inter-stand cooling element 94.

On the other hand, if it is determined at the step S105 that no operation signal for the spray is directly input from the HMI 102 (in the case of NO), the input identifier 201 a operates (at a step S109) on bases of the operation signals read at the step S103, to determine whether or not any spray pattern number is directly input from the HMI 102.

If it is determined at the step S109 that a spray pattern number is directly input from the HMI 102 (in the case of YES), the control setup determiner 201 b operates (at a step S111) to determine for a respective spray a set of control set-points based on the spray pattern number and an SGF table or a finish spray code table. More specifically, the control setup determiner 201 b operates to extract, from the SGF table storage area 206 b or the finish spray code table storage area 206 c, an SGF table or a finish spray code table that corresponds to the spray pattern number. The control setup determiner 201 b further operates to extract, from the extracted SGF table or finish spray code table, an execution parameter number that corresponds to a combination of a target plate thickness and a target plate width contained in the setup request signal. Then, the control setup determiner 201 b operates to extract, from the execution parameter table storage area 206 d, an execution parameter that corresponds to the extracted execution parameter number. The control setup determiner 201 b further operates to determine for a respective spray a set of control set-points based on the extracted execution parameter.

If it is determined at the step S109 that no spray pattern number is directly input from the HMI 102 (in the case of NO), the input identifier 201 a operates (at a step S113) on bases of the operation signals read at the step S103, to determine whether or not any spray pattern number is directly input from the level-3 calculator 101.

If it is determined at the step S113 that a spray pattern number is directly input from the level-3 calculator 101 (in the case of YES), the control setup determiner 201 b goes to the step S111 of processing.

If it is determined at the step S113 that no spray pattern number is directly input from the level-3 calculator 101 (in the case of NO), the input identifier 201 a operates (at a step S115) to determine whether or not a “0” is indicated by a spray pattern number corresponding to a steel type code contained in the setup request signal supplied from the level-3 calculator 101. More specifically, the input identifier 201 a operates to extract a steel type code from the setup request signal supplied from the level-3 calculator 101. The input identifier 201 a further operates to extract a spray pattern number corresponding to the extracted steel type code, from a GCI table stored in the GCI table storage area 206 a in the hard disc 206. Then, the input identifier 201 a operates to determine whether or not the extracted spray pattern number indicates the “0”.

If it is determined at the step S115 that the spray pattern number indicates the “0” (in the case of YES), the control setup determiner 201 b operates (at a step S119) to determine for a respective spray a set of control set-points based on a composition data and an SGF table. More specifically, the control setup determiner 201 b operates to extract, from the composition data storage area 206 e, a steel type family that corresponds to a composition data contained in the setup request signal supplied from the level-3 calculator 101. The control setup determiner 201 b further operates to extract, from the SGF table storage area 206 b, an SGF table that corresponds to the extracted steel type family. The control setup determiner 201 b still operates to extract, from the extracted SGF table, an execution parameter number that corresponds to a combination of a target plate thickness and a target plate width contained in the setup request signal. Then, the control setup determiner 201 b operates to extract, from the execution parameter table storage area 206 d, an execution parameter that corresponds to the extracted execution parameter number. The control setup determiner 201 b further operates to determine for a respective spray a set of control set-points based on the extracted execution parameter.

On the other hand, if it is determined at the step S115 that the spray pattern number does not indicate the “0” (in the case of NO), the control setup determiner 201 b operates (at a step S117) to determine for each spray a set of control set-points based on a steel type code and a finish spray table. More specifically, the control setup determiner 201 b operates to extract, from the GCI table, a spray pattern number that corresponds to the steel type code. The control setup determiner 201 b further operates to extract, from the finish spray code table storage area 206 c, a finish spray code table that corresponds to the extracted spray pattern number. The control setup determiner 201 b still operates to extract, from the extracted finish spray code table, an execution parameter number that corresponds to a combination of a target plate thickness and a target plate width contained in the setup request signal. Then, the control setup determiner 201 b operates to extract, from the execution parameter table storage area 206 d, an execution parameter that corresponds to the extracted execution parameter number. The control setup determiner 201 b further operates to determine for a respective spray a set of control set-points based on the extracted execution parameter.

The control setup determiner 201 b operates (at a step S121) to make the level-1 calculator 103 set up a control for the spray via the first network 204 for material rolling in accordance with the set of control set-points determined at the step S111, the step S117, or the step S119.

FIG. 7A and 7B illustrate a model of the control setup process for the control setup device 200 according to the first embodiment.

As illustrated in FIG. 7A and FIG. 7B, a setup request signal is supplied from the level-3 calculator 101, and (at the step S115) a spray pattern number associated with a steel type code in the setup request signal is extracted. It is now assumed that the spray pattern number is “101”.

It is further assumed that (at the step S113) the spray pattern number is not directly input from the level-3 calculator 101, and (at the step S109) the spray pattern number is not directly input from the HO 102, either.

In this situation in which the spray pattern number associated with the steel type code is “101”, the control setup determiner 201 b operates to extract, from the finish spray code table storage area 206 c, a finish spray code table that corresponds to the extracted spray pattern number “101”.

Then, assuming the setup request signal supplied from the level-3 calculator 101 as containing a combination of a target plate thickness and a target plate width being “3” and “5”, respectively, the control setup determiner 201 b operates to extract, from the extracted finish spray code table, an execution parameter number “1” that corresponds to the combination of the target plate thickness “3” and the target plate width “5” contained in the setup request signal.

Next, the control setup determiner 201 b operates to extract, from the execution parameter table storage area 206 d, an execution parameter table that corresponds to the extracted execution parameter number “1”. The control setup determiner 201 b further operates on bases of the extracted execution parameter table, to determine a control set-point for a respective spray therein.

Here, (at the step S105) if an operation signal for any spray is directly input from the HMI 102, the control setup determiner 201 b operates to make the level-1 calculator 103 set up a control for the spray, via the first network 204 for material rolling, in accordance with the operation signal directly input for the spray, irrespective of any control set-point determined for any spray based on the execution parameter table.

As will be seen from the foregoing, according to the first embodiment, there is a control setup device 200 adapted to operate when supplied with a setup request signal requesting a determination of a set of control set-points in steel type families from a level-3 calculator 101, to: extract from a composition data table a steel type family corresponding to a composition data contained in that setup request signal; extract from an SGF table as a piece of first control information an execution parameter number that corresponds to the extracted steel type family and to a combination of a target plate thickness and a target plate width contained in that setup request signal; and determine from pieces of execution parameter information a set of control set-points corresponding to that extracted execution parameter number, and operate when supplied with a setup request signal requesting a determination of a set of control set-points in steel types from the level-3 calculator 101, to: extract from a finish spray code table as a piece of second control information an execution parameter number that corresponds to a steel type and to a combination of a target plate thickness and a target plate width contained in this setup request signal; and determine from pieces of execution parameter information a set of control set-points corresponding to this extracted execution parameter number, thus allowing for parameters in rolling operation processes, more specifically, control set-points for associated sprays to be set up into particulars, without causing undue loads on the level-3 calculator 101.

It is noted that in the control setup device 200 according to the first embodiment, setups are made of control set-points of sprays for spraying cooling water in the finishing mill 9. However, liquids sprayed from sprays are not limited to cooling water, so control set-points may be set up for sprays operable to spray emulsion type lubricants between a rolling material 14 and finish rolls.

Second Embodiment

For the control setup device 200 according to the first one of embodiments, description has been made of the processing procedure for the control setup process at the finishing mill 9, by way of giving an example, which is not restrictive.

For a control setup device 200 according to a second one of embodiments, description will be made of a processing procedure for a control setup process at a roughing mill 4, by way of giving an example.

The control setup device 200 according to the second one of embodiments has a similar configuration to the control setup device 200 according to the first one of embodiments configured as shown in FIG. 1 through FIG. 5.

To this point, according to the second one of embodiments, the roughing mill 4 is involved in the control setup device 200. The roughing mill 4 is operable to reciprocate a rolling material 14 with respect to a transfer direction of the rolling material 14, while roughing. This roughing mill 4 is thus different in that a set of control set-points for a respective pray is determined in correspondence to the number of times of such reciprocation. Accordingly, description will be made about the difference.

FIG. 8A and 8B illustrate a model of the control setup process for the control setup device 200 according to the first embodiment

As illustrated in FIG. 8A and FIG. 8B, a setup request signal is supplied from the level-3 calculator 101, and (at the step S115) there is extracted a spray pattern number for the roughing mill 4 associated with a steel type code in the setup request signal. It is now assumed that the spray pattern number is “0”.

It is further assumed that (at the step S113) the spray pattern number for the roughing mill 4 is not directly input from the level-3 calculator 101, and (at the step S109) the spray pattern number for the roughing mill 4 is not directly input from the HMI 102, either.

In this situation in which the spray pattern number for the roughing mill 4 associated with the steel type code is “0”, a control setup determiner 201 b operates to extract, from an SGF table storage area 206 b, an SGF table that corresponds to a composition data contained in the setup request signal supplied from the level-3 calculator 101.

Then, assuming the setup request signal supplied from the level-3 calculator 101 as containing a combination of a target plate thickness and a target plate width being “3” and “5”, respectively, the control setup determiner 201 b operates to extract, from the extracted SGF table, an execution parameter number “1” that corresponds to the combination of the target plate thickness “3” and the target plate width “5” contained in the setup request signal.

Next, the control setup determiner 20 lb operates on bases of the extracted execution parameter number “1” and a pass number contained in the setup request signal, to extract an execution parameter from an execution parameter table storage area 206 d. The control setup determiner 201 b further operates on bases of the extracted execution parameter, to determine a set of control set-points for a respective spray therein. For instance, assuming the pass number contained in the setup request signal as being that of “7” passes, there is a set of control set-points “ON”, “OFF”, “ON”, “ON”, “OFF”, “ON”, and “OFF” set up to a first to a seventh pass for the respective spray.

As will be seen from the foregoing, according to the second embodiment, a control setup device 200 is adapted to set up a control set-point every path for a respective spray into particular, even in the case the roughing mill 4 is operated to reciprocate a rolling material 14 with respect to a transfer direction of the rolling material 14, while roughing, in addition to effects of the control setup device 200 according to the first embodiment

Third Embodiment

For the control setup device 200 according to the second one of embodiments, description has been made of the processing procedure for the control setup process at the roughing mill 4 equipped with a pair of roughing rolls, by way of giving an example, which is not restrictive.

For a control setup device 200 according to a third one of embodiments, description will be made of a processing procedure for a control setup process at a roughing mill 4 equipped with two pairs of roughing rolls, by way of giving an example.

FIG. 9 shows in a block diagram a configuration of the roughing mill 4 equipped with two pairs of roughing rolls, as it is involved in the control setup device 200 according to the third one of embodiments.

As shown in FIG. 9, the roughing mill 4 is equipped with roughing rollers 4A and 4B. The transfer line for a rolling material 14 has thereon upstream rough descalers 31A and 31B installed upstream of the roughing rollers 4A and 4B, respectively, for jetting high-pressure water to the rolling material 14, from above and below.

Further, the transfer line for the rolling material 14 has thereon downstream rough descalers 45A and 45B installed downstream of the roughing rollers 4A and 4B, respectively, for jetting high-pressure water to the rolling material 14, from above and below. The roughing roller 4A is equipped with a pair of first material-rolling roll cooling elements 41 and 42 for spraying water under pressure to an upper rough-rolling roll 4AA and a pair of second material-rolling roll cooling elements 43 and 44 for spraying water under pressure to a lower rough-rolling roll 4AA. Likewise, the roughing roller 4B is equipped with a pair of third material-rolling roll cooling elements 46 and 47 for spraying water under pressure to an upper rough-rolling roll 4BA and a pair of fourth material-rolling roll cooling elements 48 and 49 for spraying water under pressure to a lower rough-rolling roll 4BB.

According to the third one of embodiments, the roughing rollers 4A and 4B are involved in the control setup device 200. The roughing rollers 4A and 4B are each respectively operable to reciprocate a rolling material with respect to a transfer direction of the rolling material, while roughing. Accordingly, there is a set of control set-points determined in correspondence to the number of times of such reciprocation, for a respective spray for each of the roughing rollers 4A and 4B. Detailed description will be made of a control setup process of determining such a control set-point for each spray.

FIG. 10A and 10B illustrate a model of the control setup process for the control setup device 200 according to the third embodiment

As illustrated in FIG. 10A and FIG. 10B, a setup request signal is supplied from the level-3 calculator 101, and (at the step S115) there is extracted a spray pattern number for the roughing mill 4 associated with a steel type code in the setup request signal. It is now assumed that the spray pattern number is “0”.

It is further assumed that (at the step S113) the spray pattern number for the roughing mill 4 is not directly input from the level-3 calculator 101, and (at the step S109) the spray pattern number for the roughing mill 4 is not directly input from the HMI 102, either.

In this situation in which the spray pattern number for the roughing mill 4 associated with the steel type code is “0”, a control setup determiner 201 b operates to extract, from an SGF table storage area 206 b, an SGF table that corresponds to a composition data contained in the setup request signal supplied from the level-3 calculator 101.

Then, assuming the setup request signal supplied from the level-3 calculator 101 as containing a combination of a target plate thickness and a target plate width being “3” and “5”, respectively, the control setup determiner 201 b operates to extract, from the extracted SGF table, an execution parameter number “1” that corresponds to the combination of the target plate thickness “3” and the target plate width “5” contained in the setup request signal.

Next, the control setup determiner 201 b operates on bases of the extracted execution parameter number “1” and a pass schedule contained in the setup request signal, to extract an execution parameter from an execution parameter table storage area 206 d. The control setup determiner 201 b further operates on bases of the extracted execution parameter, to determine a set of control set-points for a respective associated spray. Here, the pass schedule is given as a combination between a pass number at the roughing roller 4A and a pass number at the roughing roller 4B. For instance, supposing a roughing by three passes at the roughing roller 4A and three passes at the roughing roller 4B, i.e., six passes in total, the pass schedule given is denoted “3-3”.

For instance, assuming the pass schedule contained in the setup request signal as being “3-3”, there is given a combination of a set of control set-points set up as “ON”, “OFF”, and “ON” to a first to a third pass for a respective spray at the roughing roller 4A, and a set of control set-points set up as “ON”, “OFF”, and “ON” to a first to a third pass for a respective spray at the roughing roller 4A.

As will be seen from the foregoing, the control setup device 200 according to the third embodiment is adapted to set up a control set-point every path for a respective associated spray into particular, even in the case the roughing rollers 4A and 4B are operated to reciprocate a rolling material 14 with respect to a transfer direction of the rolling material 14, while roughing respectively, in addition to effects of the control setup device 200 according to the second embodiment.

Furth Embodiment

For the control setup device 200 according to the first one of embodiments, description has been made of the processing procedure for the control setup process at the finishing mill 9, by way of giving an example, which is not restrictive.

For a control setup device 200 according to a fourth one of embodiments, description will be made of a processing procedure for a control setup process at a runout laminar spray cooler 11, by way of giving an example.

When a rolling material 14 is cooled at the runout laminar spray cooler 11, its edges are cooled with ease. As a result, the rolling material 14 tends to have temperature differences developed between a central region and the edges. In some cases, it may experience deformations due to such temperature differences.

To this point, according to the second one of embodiments, the runout laminar spray cooler 11 is involved in the control setup device 200. The runout laminar spray cooler 11 is controlled so that sprayed cooling water does not hit on edges of the rolling material 14, to prevent the rolling material 14 from being over-cooled at edges.

FIG. 11 shows in a block diagram a configuration of the runout laminar spray cooler 11 involved in the control setup device 200 according to the fourth one of embodiments. It is noted that the runout laminar spray cooler 11 has a plurality of banks in the transfer direction of the rolling material 14. Among the banks the runout laminar splay cooler 11 has, only one is depicted in FIG. 11 for the convenience of description.

As shown in FIG. 11, there is a ball screw 112 driven by rotation of a motor 116, to revolve about an axis of rotation P. As the ball screw 112 revolves, a nut member 113 thereon moves up and down. On the nut member 113 respective one-ends of first arms 114 a and 114 b are articulated. Opposite ends of the first arms 114 a and 114 b are articulated on second arms 115 a and 115 b, respectively. The second arms 115 a and 115 b have guard plates 111 a and 111 b fixed to one-ends thereof.

The rolling material 14 is coming nearer in view of the figure, and cooling water is sprayed downward from nozzles of a laminar spray 117. As the nut member 113 is downwardly moved by revolutions of the ball screw 112, the guard plate 111 a moves in a direction R1, and the guard plate 111 b moves in a direction R2. This arrangement can prevent sprayed cooling water from hitting on edges at lateral sides of the rolling material 14.

FIG. 12A and 12B illustrate a model of the control setup process for the control setup device 200 according to the fourth embodiment.

As illustrated in FIG. 12A and FIG. 12B, a setup request signal is supplied from the level-3 calculator 101, and (at the step S115) there is extracted a spray pattern number for the runout laminar spray cooler 11 associated with a steel type code in the setup request signal. It is now assumed that the spray pattern number is “0”.

It is further assumed that (at the step S113) the spray pattern number for the runout laminar spray cooler 11 is not directly input from the level-3 calculator 101, and (at the step S109) the spray pattern number for the roughing mill 4 is not directly input from the HMI 102, either.

In this situation in which the spray pattern number for the runout laminar spray cooler 11 associated with the steel type code is “0”, a control setup determiner 201 b operates to extract, from an SGF table storage area 206 b, an SGF table that corresponds to a composition data contained in the setup request signal supplied from the level-3 calculator 101.

Then, assuming the setup request signal supplied from the level-3 calculator 101 as containing a combination of a target plate thickness and a target plate width being “3” and “5”, respectively, the control setup determiner 201 b operates to extract, from the extracted SGF table, an execution parameter number “1” that corresponds to the combination of the target plate thickness “3” and the target plate width “5” contained in the setup request signal.

Next, the control setup determiner 201 b operates on bases of the extracted execution parameter number “1” and an offset amount relative to a finish delivery setup width, to extract an execution parameter from an execution parameter table storage area 206 d. The control setup determiner 201 b further operates to determine a set of control set-points to set up whether or not it employs edge masks, that is, whether or not it makes the guard plates 111 a and 111 b move in the direction R1 and the direction R2, respectively.

As will be seen from the foregoing, the control setup device 200 according to the fourth embodiment is adapted to set up a set of control set-points into particulars for motors 116 operable to make guard plates 111 a and 111 b move so that sprayed cooling water is kept from hitting on edges of a rolling material 14, to prevent the rolling material 14 from being over-cooled at edges, in addition to effects of the control setup device 200 according to the first embodiment

It is noted that the first to fourth embodiments have extracted an execution parameter number based on an SGF table stored in an SGF table storage area 206 b or a finish spray code table stored in a finish spray code table storage area 206 c, to determine from pieces of execution parameter information a set of control set-points corresponding to the extracted execution parameter number, while they are not restrictive.

For instance, there may be a control setup device 200 provided with a memory for storing a set of second GCI tables listing steel type codes associated with execution parameter codes, and adapted to operate when supplied with a setup request signal requesting a determination of a set of control set-points in steel types from a level-3 calculator, to extract from a GCI table an execution parameter number corresponding to a steel type code and a combination of a target plate thickness and a target plate width contained in the setup request signal, to determine from pieces of execution parameter information a set of control set-points corresponding to the extracted execution parameter number.

INDUSTRIAL APPLICABILITY

Embodiments herein are applicable to hot rolling systems in which a hot rolling mill is put under control for hot rolling a metal. 

1. A control setup device comprising: an execution parameter information storage area configured to store therein sets of control set-points for control of control object apparatuses and execution parameter numbers uniquely identifying the sets of control set-points, respectively associated with each other, as execution parameter information; a first control information storage area configured to store therein one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of steel type families including one or more of steel types having similar characteristics, as first control information; a second control information storage area configured to store therein one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of the steel types, as second control information; a composition information storage area configured to store therein for a respective one of the steel type families composition information representing components of the steel type family, as composition information tables; and a control setup determiner configured to operate when supplied with a setup request signal requesting a determination of a set of control set-points in the steel type families from a superior calculator connected to the control setup device, to extract from the composition information table one of the steel type families corresponding to composition information contained in the setup request signal, extract from the first control information one of the execution parameter numbers corresponding to the extracted steel type family and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number, and operate when supplied with a setup request signal requesting a determination of a set of control set-points in the steel types from the superior calculator, to extract from the second control information one of the execution parameter numbers corresponding to one of the steel types and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number.
 2. A control setup method comprising: an execution parameter information storage step of storing in memory means sets of control set-points for control of control object apparatuses and execution parameter numbers uniquely identifying the sets of control set-points, respectively associated with each other, as execution parameter information; a first control information storage step of storing in memory means one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of steel type families including one or more of steel types having similar characteristics, as first control information; a second control information storage step of storing in memory means one of the execution parameter numbers corresponding to a combination of a target plate thickness and a target plate width for each of the steel types, as second control information; a composition information storage step of storing in memory means for a respective one of the steel type families composition information representing components of the steel type family, as composition information tables; and a control setup determination step of operating when supplied with a setup request signal requesting a determination of a set of control set-points in the steel type families from a superior calculator connected to a control setup device, to extract from the composition information table one of the steel type families corresponding to composition information contained in the setup request signal, extract from the first control information one of the execution parameter numbers corresponding to the extracted steel type family and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number, and operating when supplied with a setup request signal requesting a determination of a set of control set-points in the steel types from the superior calculator, to extract from the second control information one of the execution parameter numbers corresponding to one of the steel types and to a combination of a target plate thickness and a target plate width contained in the setup request signal, and determine from the execution parameter information a set of control set-points corresponding to the extracted execution parameter number. 